U.S. patent number 5,844,601 [Application Number 08/622,476] was granted by the patent office on 1998-12-01 for video response system and method.
This patent grant is currently assigned to Hartness Technologies, LLC. Invention is credited to Alan D. Collins, Bernard M. McPheely, John G. O'Donnell.
United States Patent |
5,844,601 |
McPheely , et al. |
December 1, 1998 |
Video response system and method
Abstract
A system and method is disclosed for instructing personnel in
the operation and servicing of machinery at a plant from a
geographically remote service center employing trained personnel.
The system and method includes monitoring operating machinery at
the plant with a video camera and transmitting a video signal to a
base unit associated with the plant having a high resolution
monitor. Audio communication is also provided between plant
personnel and the personnel at the service center wherein audio
signals are received and transmitted through the base unit. The
video and audio signals are processed together at the base unit for
synchronous transmission over a telecommunication system to the
remote service center. The machinery is monitored in the plant with
a cordless portable video camera by moving the portable video
camera to a desired area of the operating machinery which needs
monitoring. Cordless headsets, worn by plant personnel attending
the machinery, are utilized to provide audio communication through
the base unit at the plant. The plant may be divided into a
plurality of machinery zones having zone interface units hard wired
to the base units. The video signal is transmitted using radio
frequency (RF) transmissions to the zone interface unit, and then
to the plant base unit. Switches may be used between the zone
interface units and the base unit to provide reception of a strong
video signal at the base units.
Inventors: |
McPheely; Bernard M. (Greer,
SC), Collins; Alan D. (Flower Mound, TX), O'Donnell; John
G. (Flower Mound, TX) |
Assignee: |
Hartness Technologies, LLC
(Greenville, SC)
|
Family
ID: |
24494314 |
Appl.
No.: |
08/622,476 |
Filed: |
March 25, 1996 |
Current U.S.
Class: |
348/143; 348/150;
348/159; 348/E7.086; 348/E7.091 |
Current CPC
Class: |
H04N
7/002 (20130101); H04N 7/181 (20130101) |
Current International
Class: |
H04N
7/18 (20060101); H04N 7/00 (20060101); H04N
007/18 (); H04N 009/47 () |
Field of
Search: |
;348/143,151,153,158,211,212,213,214,14,15
;455/33.1,33.2,54.1,56.1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Chin; Tommy P.
Assistant Examiner: Diep; Nhon T.
Attorney, Agent or Firm: Reed; Robert R. Flint; Cort
Claims
What is claimed is:
1. A method for servicing production and manufacturing machinery at
a plant from a geographically remote service center employing
trained service personnel comprising:
viewing said machinery in said plant with a wireless portable video
camera including a radio frequency transmitter for transmitting a
video signal, and moving said portable video camera to a desired
area of said machinery which needs servicing for generating said
video signal containing an image of said machinery;
providing a base unit at said plant;
transmitting said video signal from said portable video camera to
said base unit using, at least in part, said radio frequency
transmitter;
transmitting an audio only signal to said base unit using a
wireless, portable audio two-way component carried by plant
personnel at said machinery in said plant to generate said audio
only signal;
transmitting and receiving said audio only signals using a radio
frequency transmission system and a transceiver having an
associated transmitting antenna and a receiving antenna hard-wired
to said transceiver wherein said transceiver is operatively
associated with said base unit;
processing said video and audio only signals at said base unit for
transmission over a telecommunication system;
processing said video and audio only signals by converting and
compressing said video and audio only signals to provide compressed
digital signals for transmission of high quality synchronized video
and audio signals to said remote service center;
displaying said video signal on a monitor at said remote service
center;
transmitting remote audio signals from said remote center to said
base unit in said plant, and processing said remote audio signals
for retransmission as audio only signals to said audio two-way
component carried by said plant personnel at said machinery;
audibly communicating between plant personnel at said plant and
said service personnel at said remote service center using said
audio signals in real time two-way audio communications; and
providing technical assistance by said service personnel at said
remote center to said plant personnel for said machinery while
viewing said monitor and listening to said audio
communications.
2. The method of claim 1 including mounting said portable video
camera on a transportable carrier, and moving and focusing said
camera on said operating machinery for servicing by using a remote
controller.
3. The method of claim 1 including providing a fixed video camera
at a viewing area of said machinery in said plant, and controlling
the focusing of said video camera using a remote controller at said
geographically remote service center so that said service personnel
may focus upon an area of said operating machine for said
servicing.
4. The method of claim 3 including using said fixed video camera
affixed to a stationary mount in an area of said operating
machinery which is controlled with respect to pan, tilt, and
focus.
5. The method of claim 3 including using said fixed video camera
affixed to said base unit which is controlled with respect to pan,
tilt, and focus.
6. The method of claim 1 including providing a plurality of
machinery zones within said plant, having respective zone units,
and transmitting said video signal from said video camera to a
selected zone unit, and from said zone unit to said base unit so
that a video signal of high strength which provides high resolution
is received from said zone unit.
7. The method of claim 6 including switching between said zone
units depending upon the strength of said video signal to provide
reception of said video signal of high strength at said base
unit.
8. The method of claim 7 including using an automatic switch which
automatically senses the strongest signal at one of zone units and
transmits said video signal of maximum strength from said zone unit
to said base unit.
9. The method of claim 6 including transmitting said video signal
from said portable video camera to said zone units using radio
frequency (RF) transmission.
10. The method of claim 9 including hard wiring said zone unit to
said base unit.
11. The method of claim 1 including displaying said video signal
using a high-resolution, studio-grade monitor.
12. The method of claim 11 including providing a base unit video
camera at said base unit for providing a base unit video signal
which may be transmitted over said telecommunication system to said
remote service center, and providing a base unit video monitor for
displaying said video signals simultaneously with said service
center.
13. The method of claim 1 including providing a zoom unit at said
plant having a zoom video camera for zooming in on details of
machine parts and components for providing a zoom video signal of
said details for transmission to said remote service center.
14. The method of claim 1 including separating said video signal
into a plurality of bandwidths of digital signals and strapping
said bandwidths together for transmission of said first video
signal to said remote service center.
15. The method of claim 14 including strapping together three
integrated services digital network lines of said telecommunication
system, and using an inverse multiplexor device to obtain a
bandwidth sufficient for transmitting said digital signals at a
high data rate of at least 384 kilobits per second to provide a
high resolution display.
16. A video response system for communicating the operation or
servicing of production and manufacturing machinery between a plant
where the machinery is located and a remote center comprising:
a wireless, portable video camera for providing a video signal
containing an image depicting at least a portion of said machinery
in said plant and a radio frequency transmitter associated with
said video camera for transmitting said video signal;
a video receiving antenna disposed in a receiving area of said
machinery and portable video camera for receiving said video
signal;
a two-way audio only communication system for the wireless
transmission and reception of audio only signals by attending plant
personnel at said machinery;
at least a first base unit located in said plant for receiving said
video and audio only signals:
said audio communication system including a two-way wireless,
portable audio component carried by said plant personnel, and an
audio transceiver associated with said base unit, said audio
transceiver including a two-way antenna system having a receiving
antenna for receiving audio only signals from said audio component
carried by said plant personnel and a transmitting antenna for
transmitting audio only signals from said base unit to said audio
component carried by said plant personnel;
said audio transceiver being operatively associated with said base
unit; and wherein said base unit comprises;
a signal processor for receiving said video and audio only signals
to convert said signals into compressed digital signals for high
quality synchronized transmission of said video and audio signals
to said remote center; and
an output interface for delivering said compressed video and audio
digital signals in a form for delivery over a telecommunication
system
a remote audio system at said remote center for receiving said
audio signals and for transmitting remote audio signals to said
base unit for retransmission as audio only signals to said audio
component carried by said plant personnel;
so that real-time wireless video and two-way audio signals are
provided for effective operation or servicing of the machinery--for
retransmission from said base unit to said remote center.
17. The system of claim 16 wherein said audio communication system
includes a receiving antenna and a transmitting antenna wired to
said audio transceiver of said base unit for receiving and
transmitting radio frequency (RF) audio signals.
18. The system of claim 17 wherein said audio system includes at
least one wireless audio headset to be worn by said plant personnel
for communicating with said transmitting and receiving
antennas.
19. The system of claim 16 wherein said base unit includes a base
unit camera for viewing personnel at the location of said base
units and generating a base video signal, and a monitor for
displaying said camera video signal or said base video signals.
20. The system of claim 16 wherein said base unit includes a
microphone for receiving audio messages at the location of the base
unit.
21. The system of claim 16 wherein said output interface includes
an inverse multiplexor for strapping together a plurality of lines
of an integrated services digital network to transmit said digital
signals to a second base unit at said service center at a high data
rate for generating a high resolution video display at said service
center.
22. The system of claim 16 including a second base unit at said
remote service center comprising:
a video monitor for displaying said video signal from said first
base unit;
an audio transceiver for receiving said audio signal from said
first base unit, and producing an audible message at said service
center; and
a signal processor for receiving said video signal from said first
base unit, and processing said video signal for display on said
monitor.
23. The system of claim 22 wherein said video monitor includes a
high resolution monitor of studio-grade quality.
24. The system of claim 16 including at least one zone interface
unit disposed within an area of said operating machinery for
receiving said video signal from said wireless, portable video
camera and transmitting said video signal to said first base
unit.
25. The system of claim 24 including a radio frequency (RF)
transmitter associated with said portable camera for transmitting
said video signal to said zone interface unit.
26. The system of claim 24 including a plurality of said zone
interface units associated with different zones of operating
machinery, and including a switch for selecting a particular zone
interface unit to provide a video signal of high quality with
regard to the location of said portable video unit.
27. The system of claim 16 including a plurality of said zone
interface units associated with different zones of operating
machinery, and including a switch for selecting a particular zone
interface unit to provide a video signal of high quality with
regard to the location of said portable video unit.
28. The system of claim 27 wherein said first base unit is portable
and may be moved to one of said zones as desired; and including a
base unit cable for plugging said base unit into a zone interface
unit, and said zone interface unit being wired to a
telecommunication system for transmitting said video and audio
signals to said service center.
29. The system of claim 28 including a line splitter device wired
between said zone interface units and said telecommunication
system, said spliter device having a switch to transmit signals
from said zone interface unit into which said base unit is
plugged.
30. The system of claim 16 including an integrated services digital
network having a plurality of lines strapped together for
transmitting said digital signals.
31. The system of claim 16 wherein said first base unit comprises a
microphone for receiving audible messages from personnel at said
plant for conversion into said audio signals by said audio
transceiver.
32. The system of claim 16 including at least one wireless headset
to be worn by a plant attendant for communicating with said audio
system of said base unit.
33. The apparatus of the system of claim 16 wherein said first base
unit comprises a video camera affixed to said base unit which is
controllable in a pan, tilt, and focus operation.
34. The system of claim 16 wherein said wireless, portable video
camera transmits a one-way video signal to said base unit via said
video receiving antenna for retransmission to said remote
center.
35. The system of claim 34 wherein said receiving antenna is
hardwired to said base unit.
36. The system of claim 35 including a plurality of zone units
disposed in different areas of said plant where machinery is
located, each said zone unit having one of said video receiving
antennas for receiving said one-way video signal when said portable
video camera is in a selected zone wherein each said video antenna
is hardwired to said base unit.
37. The system of claim 35 wherein said base unit includes a
monitor for displaying said one-way video signal, and for
displaying other video signals transmitted from said remote center
to said base unit.
Description
BACKGROUND OF THE INVENTION
This invention relates to a system and method for servicing
machinery in operation and/or training operational personnel in an
industrial plant by service personnel and technicians at a
geographically remote service center.
Previously, it has been known to monitor the production of
machinery and processes, and communicate production and other data
to a remote facility. For example, U.S. Pat. No. 5,309,351
discloses a system for transmitting maintenance and diagnostic
information over a communication satellite between a computer or
hand held unit, and factory machinery.
It is also known to use video cameras to observe events from a
remote location. For example, U.S. Pat. No. 5,382,943 discloses a
security system which uses a video camera for monitoring the
security of a remote building site from a central control center
via radio transmission. U.S. Pat. No. 5,384,588, discloses wire and
wireless transmission of video signals, such as in a video
conferencing system, wherein the video signal may be split up into
different components for viewing different sites. U.S. Pat. No.
4,789,947 discloses a video camera mounted on a guide rack for
monitoring the condition of a bridge from a remote location. U.S.
Pat. Nos. 4,656,509 and 5,241,380 disclose track mounted video
cameras for monitoring a condition from a remote location. U.S.
Pat. No. 5,350,033 discloses a robotics inspection vehicle and
video camera operated by a joystick at a remote location using
radio transceiver devices.
However, none of the above systems and methods are suitable for
servicing machinery in operation at an industrial plant from a
remote service center, particularly where the machinery is
dispersed at several locations in the plant, and allow audio and
video communication between plant and service personnel.
Accordingly, an object of the present invention is to provide a
system and method for the servicing of machinery operating in a
plant from a geographically remote service center;
Another object of the present invention is to provide a system and
method for the remote servicing of machinery operating and/or
training at a plant facility whereby the operation of the machinery
may be viewed at a geographically remote service center at which
trained technicians may communicate with plant personnel to service
the machinery and train personnel without the need of costly
travel;
A further object of the present invention is to provide a means to
train machinery operators from a remote location so that a number
of operators at different locations can receive the best real-time
training available;
Another object of the present invention is to provide a remote
servicing system by which operating machinery at a plant may be
serviced at a remote service center by trained service personnel
wherein video monitoring may be controlled remotely by the service
personnel to allow video focusing on a desired area of the
operating machinery for servicing;
Another object of the present invention is to provide a system and
method for the remote servicing of machinery operating in a plant
by experienced service personnel at a geographically remote
location wherein machinery operating at various dispersed locations
within a plant facility, or multiple plants, may be viewed using
the system and method;
Another object of the present invention is to provide a system and
method for the servicing of machinery operating in a plant by
trained service personnel at a geographically remote location
wherein both video and audio monitoring of the machinery may be
provided at different machinery locations between service and plant
personnel to eliminate the need of costly travel for the servicing
of the machinery.
SUMMARY OF THE INVENTION
The above objectives are accomplished according to the present
invention by providing a video response system for communicating
the operation and servicing of machinery between a plant where the
machinery is located and a remote service center wherein a
wireless, portable video camera is provided having a video signal
depicting the operation of the machinery in the plant. The system
further comprises an audio unit for the wireless transmission and
reception of audio signals by attending plant personnel; and a
first base unit located in the plant for receiving the video and
audio signals. The base unit comprises an audio transceiver for
receiving audio signals from the plant personnel and for
transmitting audio signals to plant personnel, and a signal
processor for receiving the video and audio signals to convert the
signals into modulated digital signals for transmission to remote
service center. An output interface provides the digital signals in
a form to be delivered over a telecommunication system to the
service center.
Preferably, a receiving antenna and a transmitting antenna are
wired to the audio transceiver at the base unit for receiving and
transmitting radio frequency (RF) audio signals. The audio unit
includes at least one wireless audio headset to be worn by plant
personnel for communicating with transmitting and receiving
antennas. The output interface may include an inverse multiplexor
for strapping together multiple lines of an integrated services
digital network to transmit digital signals to a second base unit
at the service center at a high data rate for generating a high
resolution video display at the service center.
The base unit may also include a base unit camera for viewing
personnel at the location of the base units and generating a base
video signal, and a monitor for displaying the camera video signals
or base video signals.
A second base unit is provided at the remote service center having
a video monitor for displaying video signals from the first base
unit; and an audio transceiver for receiving audio signals from the
first base unit, and producing an audible message at the service
center. The second base unit includes a signal processor for
receiving video signals from the first base unit, and processing
the video signal for display on a monitor.
At least one zone interface unit is located within an area of the
operating machinery for receiving video signals from the wireless,
portable video camera and transmits the video signal to the first
base unit. A radio frequency (RF) transmitter is associated with
the portable camera for transmitting video signals to the zone
interface unit. Preferably, a plurality of zone interface units is
associated with different zones of operating machinery, and a
switch is provided for selecting a particular zone interface unit
to provide a video signal of high quality with regard to the
location of the portable video unit.
In an alternate arrangement, the base unit maybe portable and may
be moved to one of the zones as desired. A base unit cable is
provided for plugging the base unit into a zone interface unit. The
zone interface unit is wired to the telecommunication system for
transmitting video and audio signals to the service center. A
circuit splitter is wired between the zone interface units and the
telecommunication system for automatically transmitting signals
from the zone interface unit into which the base unit is
plugged.
In accordance with other aspects of the invention, a method is
disclosed which includes servicing machinery at a plant from a
geographically remote service center which employs trained service
personnel for monitoring operating machinery at the plant by use of
a video camera having a video signal. The method includes
transmitting video signals to a base unit associated with the
plant; processing the video signal at the base unit for
transmission over a telecommunication system; transmitting the
video signal from the base unit to the remote service center over
the telecommunication system; and displaying the video signal on a
monitor at the remote service center. Audio communication is
provided between plant personnel at the plant and the service
personnel at the remote service center; and the method includes
providing service assistance by the service personnel to the plant
personnel for operating the machinery while viewing the monitor and
listening to audio communication. Preferably, the method includes
monitoring the operating machinery in the plant with a wireless,
portable video camera which provides a first video signal. The
method includes moving the portable video camera to a desired area
of the operating machinery which needs servicing. The portable
video camera maybe mounted on a transportable carrier, and is moved
and focused on the operating machinery for servicing by using a
remote controller. In an alternate arrangement, the focusing of the
video camera maybe controlled by using a remote controller at the
geographically remote service center so that service personnel may
direct the focusing upon an area of the operating machine for
servicing. In this case, a video camera maybe affixed to a
stationary mount in an area of the operating machinery and
controlled with respect to pan, tilt, and focus using remote
control.
The method contemplates dividing the plant into a plurality of
machinery zones, having respective zone interface units, and
transmitting the video signal from the video camera to a selected
zone interface unit, and from the zone interface unit to the base
unit so that a video signal of high strength which provides high
resolution is received from the zone unit. Switching between the
zone units may be done in accordance with the strength of the video
signal to provide reception of the video signal of high strength at
the base unit. Use of an automatic switch may be had which
automatically senses the strongest signal at one of the plugs
having a zone unit and transmits the video signal of maximum
strength from zone unit to base unit. The method includes
transmitting the video signal from the portable video camera to the
zone units using radio frequency (RF) transmission. The method
contemplates the use of a zoom unit at the plant having a zoom
video camera for zooming in on details of machine parts and
components for providing a zoom video signal of details for
transmission to the remote service center. Processing of the audio
and video signals is done by converting and compressing the signals
to provide modulated digital signals for transmission to the remote
service center. The method also includes separating the signals
into a plurality of bandwidths of digital signals, and strapping
the bandwidths together for transmission to the remote service
system.
DESCRIPTION OF THE DRAWINGS
The construction designed to carry out the invention will
hereinafter be described, together with other features thereof.
The invention will be more readily understood from a reading of the
following specification and by reference to the accompanying
drawings forming a part thereof, wherein an example of the
invention is shown and wherein:
FIG. 1 is a simplified block diagram of a basic system and method
for the servicing of in-plant machinery and/or training of
machinery operators from a geographically remote service center
according to the invention;
FIG. 2 is a detailed schematic and block diagram of a system and
method for servicing in-plant machinery by trained service
personnel at a geographically remote service center according to
the invention wherein machinery maybe located at different zones in
a plant facility;
FIG. 3 is a detailed schematic and block diagram of a system and
method for the servicing of in-plant machinery from a
geographically remote service center where the machinery maybe
located at different plant locations and/or zones according to the
invention;
FIG. 4 is a schematic diagram of a remote service center from which
machinery operating at a geographically remote plant facility may
be serviced according to the system and method of the present
invention;
FIG. 5 is a schematic diagram of an alternate embodiment of the
system where a base unit may be employed at one of a plurality of
plant zones, and automatically selected for transmitting video
signals of the machinery at that zone;
FIG. 6 is a schematic diagram of another embodiment of the system
where the scanning and focusing of a video camera located at the
machinery can be remotely controlled from a base unit location,
and
FIG. 7 is a schematic diagram of a base unit according to the
invention for use in the system and method of the invention.
DESCRIPTION OF A PREFERRED EMBODIMENT
Referring now to the drawings, the invention will now be described
in more detail. As can best been seen in FIGS. 1 and 2, an
embodiment of a video service system, designated generally as A, is
illustrated for servicing machinery, or training machinery
operators, from a geographically remote location in accordance with
the invention. Video service system A includes a base unit B
located within a plant 10 in which the machine is to be serviced.
There is a portable video unit C located at the machinery for
monitoring the operating machinery having a wireless, video camera
11 with a video output which provides a first video signal V1 of
the operating machinery which is transmitted to base unit B. The
video signal is processed by the base unit, and transmitted over
telephone lines 92 as video signal V2 to a remote service center D.
Various other video signals V2-V6, to be described more fully
hereafter, audio signals A1,and control signals S are processed and
transmitted over an integrated services digital network (ISDN) 21
between plant 10 and remote service center D. At remote service
center D, trained service personnel and technicians may study a
video display of the operating machinery and communicate orally
with plant personnel attending the machinery to provide servicing
and/or training.
As can best be seen in FIG. 2, base unit B and portable unit C are
located in plant 10, which may be a typical manufacturing plant
facility having machinery and/or processes that must be serviced on
a routine basis. Portable unit C may be located in any one of a
plurality of zones "Z" within the plant. Portable unit C transmits
first video signal V1 from the plant, preferably using an antenna
of a zone unit, designated generally as 12, to base unit B. Base
unit B may be located at a central location in a plant control area
16 (FIG. 2), or may be moveable and located at the machinery (FIG.
5). As illustrated in FIG. 2, zone units 12 include zone plugs
19a-19d at zone interface units 12a-12d located in zones Z1-Z4
respectively, to provide transmission of a high quality video
signal over wiring to the base unit as portable video unit C is
moved within the plant. The zone interface units include radio
frequency (RF) receivers hard wired through zone plugs 19a-19d and
cables 48a-48d back to base unit B through a zone control switch
66. The zone control switch connects the video signal for viewing
on a high resolution, studio grade monitor 54 having 450 horizontal
lines, as is available from the Sony Corporation. Switch 66 may be
manual, or may be an automatic switch of the cellular type which
automatically picks up and transmits the strongest signal from the
zones. Zone lines 15 may divide the plant into individual zones Z
to provide the best video signal transmission quality to the base
unit from a particular area of the plant. Physical barriers and
electrical interference signals may determine the shape and size of
the individual zones "Z" within plant 10.
One or more stationary video cameras 11a may also be utilized in
addition to portable camera 11 to provide video coverage for the
machinery or process in each zone. The stationary video cameras may
be affixed to ceilings, walls, or stands as needed to adequately
cover the operating machinery (FIGS. 2 and 5). Stationary cameras
11a may also be hard wired to base unit B using a cable 43
connected to zone plugs 19a-19d (e.g. 19d illustrated) for
transmission of video signals. In this case, standard switching may
be employed to select wireless camera 11 or stationary camera
11a.
In accordance with another aspect of the invention, as can best be
seen in FIG. 3, multiple plant locations each having a plurality of
zones may be serviced according to the invention. For example,
there may be three plants 16, 18, and 20. Each plant may have any
number of zones, or only a single zone, as illustrated at plant 20.
Each plant preferably has at least one portable unit C to generate
a video signal of the plant's machinery which is transmitted by a
RF signal to a zone unit 12. Zone units 12a-12f are hard wired to a
base unit B at each plant. For example portable units and base
units C1 and B1, C2 and B2, and C3 and B3 may be employed at plants
16, 18, and 20, respectively.
As can best be seen in FIG. 2, portable unit C includes wheels 32
for manual transportation of portable unit C to various zones where
the operating machinery is located in plant 10. The portable unit
may include a battery pack 34 which can be periodically charged
using a battery charger unit 36 to make the portable unit
independent of a power supply from the plant, and more portable.
Portable video camera 11 is included in the portable unit to
provide video signals of operating machinery 38 to be observed
and/or serviced. The camera 11 is wireless, and can be a standard
pan-tilt-zoom (PTZ) camera available in the industry, such as a
model CCD-TR23 available from Sony Corporation of Dallas, Tex. The
portable unit has a video antenna 40 and a RF unit for transmitting
first video signal V1 to a zone unit and antenna 12. The video
antenna and RF unit is available in the industry, such as model
BE420T available from Premier Wireless, Inc. of California.
Portable video camera 11 can be equipped with a battery and an RF
unit so it can be detached from the portable unit, hand held and
carried by an operator 74 to focus on any specified area of the
machine. Optional stationary camera 11a can be used in lieu of, or
in addition to camera 11.
Portable video camera 11, or optional stationary video camera 11a,
can be positioned and operated by an operator to tilt-pan-zoom on a
portion of the machinery necessary for servicing and/or training.
In this embodiment of the invention, camera focusing can be
directed by trained service personnel 78 at the remote service
center D who know exactly what area of the machine to focus on for
servicing, training or repairing. Instructions are transmitted by
the audio signals A1 or A1' to the operator 74 located at the
machine by way of base unit F to base unit B and on to the
operator. The portable unit operator can be instructed to better
focus on the plant machinery or process from both the plant control
area 16 and/or by instructions from service personnel at the remote
service center D.
In an advantageous aspect of the invention, standard zoom units 60
(FIG. 2) and 86 (FIG. 4) are provided in the plant and service
center, and include zoom cameras 62 and 94 for detailed viewing of
a subject such as a machine part. For example, the zoom camera 62
can provide a zoom video signal of a zoom subject 64 for
transmission as another video signal V4 (FIG. 1) for possible
viewing on the monitor 80 at the remote service center. The zoom
subject can be a component part from plant machinery 38, a process
control chart, a circuit board or any similar servicing aid or
prop, and the like. Base video camera 13 and zoom camera 62 are
directly connected to system device E of the base unit. Remote IR
control pad 68 can control both the base unit camera 13 and the
zoom camera 62.
Referring now to signal processing, base unit B generates a second
video signal V2 to be transmitted by a telecommunications system
line wherein the system may include a plurality of ISDN lines 21a,
21b, 21c (FIG. 1) in the preferred embodiment. A communication
interface 23 receives digital video signal V2, as well as audio
signals A1over ISDN line 21, and transmits them to a remote service
center D over ISDN line 92. Communication interface 23 may be
standard land based lines and/or a satellite system, and the like.
It is to understood herein, that the term video signal is used to
refer to the singular and a plurality of signals, and line is used
to refer to the singular and a multiple of lines.
In an advantageous aspect of the invention, as can best be seen in
FIG. 7, base unit B includes an audio transceiver component 56
having a receiving antenna 70a and a transmitting antenna 70b. The
audio component is connected to and controlled by the system device
E. Audio signals also come directly from a microphone 72 at the
base unit to signal processing device E. The video/audio signals
are received by base unit B, and processed by signal processor
device E, and transmitted as second video signals V2 over ISDN
lines 21 to communication interface 23 and service center D. The
video/audio signals are compressed and transmitted over the
communication lines at a high rate to generate high quality
transmissions between the base unit B and the service center D.
Signal processor device E may include a suitable "CODEC" component
which digitizes, compresses and codes/decodes the video and audio
signals (FIG. 7).
The CODEC component may also receive video signals V1 from the
portable unit by way of cable 48. Base unit camera 13 provides
another set of video signals V3 to the CODEC component of device E.
The CODEC is a modulator/demodulator (modem) that converts the
pictures and sound to compressed digital signals for transmission
to a receiving unit. A suitable CODEC device is Model VM 4500
manufactured by PictureTel Corporation of Danvers, Mass.
Preferably, the base unit also includes an inverse multiplexor
(IMUX) device E', connected to the CODEC. The CODEC converts
pictures and sound to digital signals for the IMUX to transmit at a
high data rate to the communications interface 23 and further to
another base unit F at remote service center D. Real-time video
pictures may be observed at a remote location of up to 30 frames
per second with 450 lines of resolution on high resolution monitor
54. The IMUX divides the audio/video signals at their origin and
recombine the audio/video signals at the remote location. The
inverse multiplexor is included in both base units B, F (FIG. 3),
and B' (FIG. 5). The IMUX "straps" the bandwidth of three ISDN
lines together to get a data transfer rate of 384 Kilobits per
second (Kbps). A suitable IMUX device is model no. MBB BRI 4U
manufactured by Ascend of Almeda, Calif. The ISDN lines 21 may be a
basic rate interface (BRI) type having two "B" channels each of
which has a data rate of 64 Kilobits per second. Therefore, each
ISDN line 21a, 21b and 21c has bandwidth of 128 Kbps. To transmit a
high quality video picture for machinery servicing and/or training
according to the invention, the three ISDN lines 21a, 21b, and 21c
are used to provide excellent video pictures. The ISDN lines
combine to give the desired data rate of 384 Kilobits per second
for video/audio signals. The video/audio signals are received by
another IMUX device G' at service center D which recombines the
signals (FIG. 4). A video picture is viewed on the high resolution
monitor at the remote service center for a high resolution
real-time picture.
Base units B, F, and B' (FIG. 5) may include standard operational
computer logic equipment and software components in addition to
audio component 56, the CODEC component E, and IMUX device E'. The
base unit F at remote Center D (FIG. 4) includes components at 80,
56, G, G' like in base unit B at the plant 10 (FIG. 2). A suitable
audio transceiver 56 for base units B and F is available from Telex
Communications Incorporated of Madina, Ohio, and transmits and
receives signals from wireless headsets 74, 76, and 78. Typical
base unit cameras 13 and 84 may be Power Cam cameras manufactured
by PictureTel Corporation. Cameras 13 and 84 of base units B and F
can be controlled by infrared (IR) remote control pads 68 and 93,
which are also used as a general IR remote control device for the
base units (FIGS. 2, 4, and 5). For example, video signal V3 from
camera 13 depicting a control area subject 58 can be viewed on a
studio-grade monitor 80 at the remote service center D (FIG. 4).
Electronically steerable microphones 72 and 82 on the base units B
and F provide excellent quality audio reception from subjects 58
and 98. A suitable microphone in the industry is the Power Mic as
manufactured by PictureTel Corporation. A video cartridge recording
device (VCR) 55 may be included in the base unit (FIG. 7) as
standard equipment. The VCR can record what is being monitored for
reference and playback later.
In operation, second video signal V2 (and/or V3 or V4) is received
by remote base unit F at service center D. The video/audio signals
may be selectively received over ISDN line 21 from any plant 10
(FIGS. 2 and 5) or plant 16, 18, 20 (FIG. 3) for evaluation.
Focusing and scanning of camera 11 of portable unit C is preferably
controlled by an operator at portable unit C. Stationary camera 11a
may be controlled by RF remote control signals from remote
controller 68 (FIG. 2) or 93 (FIG. 4). The control signals are
transmitted from base unit B over zone lines 48 and camera lines
43. Control signals from controller 93 are transmitted to base unit
F and then to base unit B over ISDN lines 92, 21.
Audio signals A1may be transmitted in both directions between
personnel at portable unit C, plant base unit B, and service center
base unit F. Service assistance is provided for the machinery
within a selected plant by trained technicians based at remote
service center D based on audio signal A1 and video signal V2, V3
and/or V4. Audio signal A1 may be transmitted between base unit B
and base unit F, or pass directly by audio signals A1' between the
service center base unit F and the portable unit C (FIG. 1). Audio
signals Al can be transmitted along with the video signals V2-V6 by
way of the same ISDN interface 23, or audio signals A1' may be
transmitted over separate standard analog telephone sets and lines
(FIG. 1).
As previously disclosed, the antenna 70a is provided on base unit B
to receive audio signals. The antenna can receive signals directly
from operator 74, as illustrated in FIG. 2. The audio signal is
transmitted by the other antenna 70b to another control area
operator or supervisor 76 at the plant base unit. Wireless headsets
are used by the operators and each headset has noise cancellation,
adjustable volume control and a lockable transmitter microphone. A
suitable headset is available in the industry as manufactured by
Telex Communications Inc. of Madina, Ohio. The audio transceiver
unit 56 is preferably installed within the base unit B to provide
audio communication links. The transceiver unit can also be a part
of the zone unit 12 to help improve the quality of the audio
signals. Communication of audio messages can also be provided by
standard analog phone sets and telephone lines between any two
locations in the network of the system.
As can best be seen in FIG. 4, the video service system at service
center D includes base unit F with components which are essentially
the same as those of base unit B, as described above. However,
there may be some differences as necessary to best function as a
remote service and/or training center. For example, a service
center operator 78 can communicate using a headset and RF signals
to the receiving antenna 100a and from the transmitting antenna
100b, or alternately by the preferred hard-wired, audio cable 57
for improved audio quality. Center base unit F receives and
processes the video/audio signals via the ISDN network and
generates a combined and decompressed video signal, corresponding
to video signals V1, V2, V3, and/or V4 for displaying on monitor
80. The combining of signals is by the IMUX device G' and
decompression and decoding is by the CODEC component of device G.
These same components process video signals from center camera 84
and the zoom camera 94 for transmission to the plant base unit B as
video signals V5 and V6 (FIG. 1). Once again, the zoom unit 86 with
its zoom camera 94 can observe subject 96 at close range, and the
base unit F can generate video signals V5 for transmission to any
plant. Remote switch 98 is essentially a standard AB switch which
can be used to allow personnel at the service center to select
which video signals V2-V4 from available cameras located at the
plants are to be processed for viewing at any particular time. The
video/audio signals are transmitted between the plant area and the
remote service center for full two-way teleconferencing capability
between plant personnel and service center personnel.
The pictures observed on the screen of monitors 54 and 80 can be
selected from any of the available subjects observed by the various
cameras 11, 11a, 13, 84, and 94 in the video service system A. The
pictures being observed on monitors 54 and 80 may be controlled by
respective plant remote controller 68 or center remote controller
93. Control signals from the remote service center IR remote
controller 93 can be received by the base unit F and transmitted to
base unit B as control signals S (FIG. 1), as described above. The
extent to which control signals S can be used at a plant control
area depends on what components are hardwired to system device E of
the base unit B. For example, the stationery camera 11a may be
controlled from the remote service center.
As can best be seen in FIG. 5, an alternate embodiment of a system
and method according to the invention includes a base unit B'
having a base unit cabinet 50 on wheels 59 for rolling the base
unit to any zone or location in the plant. For example, the base
unit can be located in a control area adjacent the machine subject
38 in zone Z4 as illustrated. The zone unit 12 is hard wired to the
base unit device E using a cable 48. The ISDN lines 21 from the
communications interface 23 connect with the plant 10 at a line
splitter device 67 which can select the zone plug which the base
unit is plugged into for transmission to the service center. The
splitter device may be a manual switch or an automatic switch to
automatically connect the lines from the splitter device into which
the the base unit is plugged. The automatic switch may be any
suitable device for automatically sensing the zone plug to be in
the circuit for proper routing; such as relays and phone jacks
which are interconnected with a circuit board for making the proper
connection. When the IMUX device E' is connected with a respective
zone plug 19, the system is automatically connected with the
outside telecommunication network. Zones Z1-Z4 have zone plugs
19a-19d hard wired by cables 48a-48d to the splitter device. The
base unit device E is hard wired to a zone plug (19d) by a cable 41
to provide a three-wire ISD network service 41a, 41b, 41c to the
base unit system device E. The first video signal V1 may be
transmitted by direct RF transmissions from camera 11 at portable
unit C to the zone unit 12. The stationary camera 11a at zone 24 is
also connected to the base unit device E by a cable 43 connected to
zone plug 19d. Along with the base unit camera 13, the machine
subject 38 may be observed by three cameras. Each camera can
concentrate on a different portion of the machine or process and
portable unit camera 11 can be hand carried by a control area
operator 76. Components associated with the base unit of this
alternate means are generally the same including the remote control
pad 68, the zoom unit 60, the audio transceiver 56, the studio
grade monitor 54 and the microphone 72. The control area operator
76 can have a headset and perform all the duties associated with
the machine subject, the portable unit C and other service and/or
teaching needs as instructed. The zone plug 19 plugged into by base
unit B will be activated.
In another embodiment, a method and system for remote wireless
control of portable unit C is illustrated in FIG. 6, using radio
frequency (RF) transmissions. A camera control transceiver unit H
may be added to plant base unit B for transmitting and receiving RF
control signal S' to and from a camera control unit 14 at the
portable unit C. A hand held remote device 69 can be used to
generate RF control signals for the camera 11. The control signals
can be transmitted and received by the control unit 14 by RF
transmissions to and from the antenna unit 22. A cable 15 connects
the antenna unit to the control transceiver unit H. The camera 11
is remotely controlled to tilt-pan-zoom and display components of
the machinery for servicing and/or training without the use of an
operator at the machine. Preferably, portable cameras 11 can also
be remotely controlled from service center D for this remote
wireless embodiment of the invention. For this purpose, an
additional cable 15a is provided between system device E and the
transceiver unit H. This allows a portable camera 11 to be remotely
controlled from the remote service center.
The embodiments illustrated in FIGS. 5 and 6 are useful in plants
where video signals are not obstructed and in plants of a small
size. A further embodiment may be realized by not having a portable
unit C and base unit B can be located adjacent the machine subject
38, such as in FIG. 5. Video signals from camera 13 to base unit
system device E are hardwire transmitted within the base unit and
camera control signals are realized by the use of the IR remote
control pad 68. For example, this embodiment is useful in plants
where adequate floor space exists in the area of the plant machine
subject 38 so that the base unit B with camera 13 can remain in one
location to pan-tilt-zoom for adequate viewing of the machine
and/or process at the remote service center.
An alternate telecommunications network for use with the system of
this invention is the special "T-1" circuit from communication
carriers. The T-1 circuit provides 24 channels of data. The use of
T-1 circuits is within the scope of this invention when using six
T-1 lines for the system of this invention for giving the bandwidth
needed. Using an enhanced bandwidth for providing a higher quality
video signal, a primary rate interface (PRI) of the ISDN network
can also be used to provide 23 channels giving a data rate of 1,544
Kilobits per second.
While a preferred embodiment of the invention has been described
using specific terms, such description is for illustrative purposes
only, and it is to be understood that changes and variations may be
made without departing from the spirit or scope of the following
claims.
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